Sheath for enclosing a case of a secondary battery

ABSTRACT

A secondary battery includes an electrode assembly having first and second electrodes and a separator, a pouch type case for receiving the electrode assembly, and a sheath for enclosing outer sides of the case. The sheath can prevent damage to the pouch in electronic devices to which the secondary battery is applicable as an inner pack type.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of prior U.S. application Ser. No.11/407,350 filed Apr. 20, 2006, now U.S. Pat. No. 8,632,909, which isherein incorporated by reference in its entirety, which claims thebenefit of Korean Patent Application No. 10-2005-0035291, filed Apr. 27,2005, the entire contents of which is also incorporated herein byreference.

BACKGROUND OF THE INVENTION

Field of the invention

The present invention relates to a secondary battery, and moreparticularly to a pouch type lithium secondary battery which has anelectrode assembly received in a pouch.

Description of the Prior Art

Secondary batteries use a non-aqueous electrolyte because of thereactivity between lithium and water. The non-aqueous electrolyte may bea solid polymer containing lithium salts, or liquid in which lithiumsalts are dissociated from organic solvent.

The secondary batteries can be classified, according to the kind ofelectrolyte, into a lithium metal battery and a lithium ion batterywhich use a liquid electrolyte, and a lithium ion polymer battery usingpolymer solid electrolyte.

In complete solid type lithium ion polymer batteries, there is noproblem of leakage of the organic electrolyte. In gel type lithium ionpolymer batteries containing organic electrolyte, the leakage of theelectrolyte also can be easily prevented in comparison with lithium ionbatteries using liquid electrolyte. For example, the lithium ion polymerbattery may use a pouch as a case for an electrode assembly, instead ofa metal can.

The pouch is made of multi-layer film generally having a metal foillayer and a synthetic resin layer covering the metal foil layer. Thepouch makes it possible to remarkably reduce the weight of the battery,in comparison to when the metal can is used as the case for theelectrode assembly. In the multilayer pouch, the foil is generally madeof an aluminum material. The polymer layer forming an inner layer of thepouch protects the metal foil from the electrolyte, and prevents anelectric short-circuiting between anode and cathode, and electrode tabs.

In order to form a pouch type lithium secondary battery, first, an anodeplate, a separator, and a cathode plate are sequentially stacked andthen rolled so as to form is an electrode assembly. Next, the electrodeassembly is disposed in a fitted pouch. Then, upper and lower pouchfilms are heated and fusion-welded at open edge of the pouch so as toseal the pouch, thereby forming the pouch type bare cell battery.

Such a bare cell battery may form an inner pack type battery. The innerpack type battery refers to a battery like a bare cell battery which isdirectly inserted into the body of an electronic device such as adigital camera or a digital camcorder requiring the secondary batteryand which is then covered with a cover member forming an exteriorsurface of the electronic device. The inner pack type battery has anexcellent merit of enduring exterior impact.

Specifically, elements or structure, such as a protection circuit moduleconnected to the electrodes of the bare cell battery, or a positivetemperature coefficient element, is mounted in the body of theelectronic device.

Therefore, in the case of the inner pack type secondary battery in whicha protection circuit module, a positive temperature coefficient element,etc. are mounted in a body of an electronic device, just the protectioncircuit module can be replaced with a new module when a protectioncircuit is damaged. Therefore, the inner pack type secondary battery hasan improved yield and a less chance of being exposed to exterior impact,in comparison with the secondary battery integrated with the protectioncircuit module.

However, the conventional secondary battery where the electrode assemblyis received in the soft pouch has a problem in that a soft pouch may beeasily damaged during mounting of the secondary battery in theelectronic device.

SUMMARY OF THE INVENTION

Accordingly, the present invention has been made to solve theabove-mentioned problems occurring in the prior art, and an object ofthe present invention is to provide a secondary battery which includes asheath for enclosing the outside of a pouch, thereby preventing a softpouch from being damaged.

In order to accomplish the object of the present invention, there isprovided a secondary battery which comprises: an electrode assemblycomprising a first electrode plate, a second electrode plate, and aseparator interposed between the first electrode plate and the secondelectrode plate; a pouch having a case for receiving the electrodeassembly; and a sheath for enclosing the pouch. Preferably, the sheathencloses sides of the pouch in rounding.

According to an aspect of the present invention, the sheath ispreferably formed with material having a mechanical strength higher thanthat of material forming the case, in order to reinforce the strength ofthe case. The sheath may be made of stainless steel, so as to be formedas a foil. Furthermore, the sheath may be made of synthetic resin. Inaddition, the sheath has a thickness of less than 0.1 mm.

According to still an aspect of the present invention, the sheath has alower surface portion which is in contact with a lower surface of thepouch, side surface portions which are in contact with a side surface ofthe pouch, and upper surface portions which are in contact with an uppersurface. Further, the side surface portions of the sheath are formed atboth edges of the lower surface portion of the sheath, and the uppersurface portions of the sheath are connected to the side surfaceportions around the lower surface portion of the sheath. Further, thelower surface portion of the sheath has an area corresponding to that ofthe lower surface of the pouch, and the side is surface portions of thesheath have an area corresponding to that of the side surface of thepouch.

According to yet an aspect of the present invention, the sheath includesa lower surface portion which is in contact with a lower surface of thepouch, side surface portions which are in contact with side surfaces ofthe pouch, respectively, upper surface portions which are in contactwith an upper surface of the pouch, and a rear surface portion which isin contact with a rear surface of the pouch. Here, the rear surfaceportion of the sheath has an area corresponding to a rear surface of thepouch, and is integrated with the lower surface portion of the sheath.

According to still yet an aspect of the present invention, the sheathincludes a first side sheath and a second side sheath which cover bothsides of the pouch respectively. Here, the left side sheath and theright side sheath respectively have a lower surface portion which is incontact with a lower surface of the pouch, a side surface portion whichis in contact with a side surface of the pouch, and an upper surfaceportion which is in contact with an upper surface of the pouch, thelower surface portion and the upper surface portion of each of the leftside sheath and the right side sheath have areas corresponding to halfareas of the lower surface and the upper surface of the pouchrespectively. Furthermore, each of the left side sheath and the rightside sheath further has a rear surface portion which is in contact withthe rear portion of the pouch. Each of the left side sheath and theright side sheath are integrally formed by molding.

According to a further aspect of the present invention, the sheathincludes an upper sheath and a lower sheath which are coupled to eachother to cover an upper portion and a lower portion of the pouch. Here,the upper sheath has an upper surface is portion which is in contactwith an upper surface of the pouch and side surface portions which areformed at both edges of the upper surface thereof so as to contact sidesurfaces of the pouch, and the lower sheath has a lower surface portionwhich is in contact with a lower surface of the pouch and side surfacesof the pouch which are formed at both edges of the lower surface thereofso as to contact of a lower surface of the pouch. The upper sheath andthe lower sheath further have a rear surface portion which is in contactwith a rear surface of the pouch respectively. Further, each of theupper and lower sheaths is integrally formed by molding.

According to another aspect of the present invention, the sheath hasinformation including either a serial number of the secondary battery orthe manufacturer, which is printed on an exterior surface thereof.

According to yet an aspect of the present invention, the secondarybattery is an inner pack battery.

According to still another aspect of the present invention, a secondarybattery includes: an electrode assembly comprising a first electrodeplate having a first electrode tab, a second electrode plate having asecond electrode tab, and a separator interposed between the firstelectrode plate and the second electrode plate; a pouch having a casereceiving the electrode assembly; and a sheath covering at least sidesof the pouch. The sheath may further enclose a rear surface of the pouchwhich is opposite to a front surface from which the first and secondelectrode tabs extend. The sheath may be a single sheath which is rolledover the pouch or composed of a first sheath and a second sheath eachwhich cover a half of the pouch to cover the pouch.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the present invention, and many of theis above and other features and advantages of the present invention,will be readily apparent as the same becomes better understood byreference to the following detailed description when considered inconjunction with the accompanying drawings in which like referencesymbols indicate the same or similar components, wherein:

FIG. 1A is an exploded perspective view showing a secondary batteryHaving an electrode assembly and a case;

FIG. 1B is a plan view showing a sheath for a case according to anembodiment of the present invention;

FIG. 2 is a perspective view showing the sheath and the pouch.

FIG. 3 is a plan view showing a sheath according to another embodimentof the present invention;

FIG. 4 is a perspective view showing a sheath according to still anotherembodiment of the present invention;

FIG. 5 is a perspective view showing a sheath according to yet anotherembodiment of the present invention; and

FIG. 6 is an exploded perspective view showing an electronic device towhich a secondary battery according to the present invention is applied.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, a secondary battery according to the present invention willbe described with reference to the accompanying drawings.

FIG. 1A is an exploded perspective view showing a secondary batteryhaving an electrode assembly and a case. FIG. 1B is a plan view showinga sheath for a case according to an embodiment of the present invention.FIG. 2 is a perspective view showing the sheath and the pouch FIG. 6 isan exploded perspective view showing an electronic device to which asecondary battery according to the present invention is applied.

Referring to FIGS. 1A, 1B and 2, the lithium secondary battery 100according to the embodiment of the present invention includes anelectrode assembly 110, a pouch 200 having a case 120 in which theelectrode assembly 110 is received, and a sheath 210 for enclosing thepouch 200.

The electrode assembly 110 includes first and second electrode plates111 and 115 coated with first and second active material layers (notshown), and a separator 113 interposed between the first and secondelectrode plates 111 and 115 so as to prevent an electricshort-circuiting between the first and second electrode plates 111 and115 as well as to allow only the movement of lithium ions. The electrodeassembly 110 is rolled several times. The first and second electrodeplates 111 and 115 have first and second electrode tabs 111 a and 115 acoupled thereto, respectively. The first electrode plate 111 may form ananode plate, and the second electrode plate 115 form a cathode plate. Inthis case, the anode plate 111 is made of an aluminum material, and thecathode plate 115 is made of an copper material. On the other hand, theseparator 113 is generally made of polyethylene resin or polypropyleneresin. However, the present invention does not limit the material ofthese elements to those mentioned above.

Chalcogenide compounds, for example composite metal oxides such as isLiCoO₂, LiMn₂O₄, LiNiO₂, LiNiO₂, LiNi_((1-x))Co_(x)O₂ (0<x<1), andLiMnO₂, are used as the anode active material. Carbon-based materials,Si, Sn, Tin oxide, composite tin alloys, transition metal oxide, andlithium metal oxide, etc. are used as the cathode active material.

The case 120 includes a first region 121 having a recess 121 a with apredetermined depth in order to receive the electrode assembly 110 and aflange member 121 b, and a second region 122 with an area enough tocover the recess 121 a of the first region 121. The case 120 is made ofa pouch film in which an adhesive layer is coated on one surface of analuminum foil and an insulation layer is coated on the other surface ofthe aluminum foil. The adhesive layer is formed with denaturalizedpolypropylene resin such as casted polypropylene (CPP) resin, and theinsulation layer is made of synthetic resin such as nylon orpolyethyleneterephtalate (PET). However, the present invention does notlimit the material of the case 120 to those mentioned above.

Further, the recess 121 a of the pouch is formed with a predetermineddepth, while the first and second electrode tabs 111 a and 115 aconnected to the electrode assembly 110 extend at a desired distanceoutward from an edge of the case 120, i.e. the flange member 121 b.

The sheath 210 has a lower surface portion 211 that is in contact with alower surface 201 of the pouch 200, side surface portions 212 that is incontact with side surfaces 202 of the pouch 200 respectively, and anupper surface portion 213 that is in contact with an upper surface 203of the pouch 200. The sheath 210 is formed in such a manner that bothside surface portions 212 are connected to both edges of the lowersurface 211 respectively, and the upper surface portions 213 arerespectively formed at is a side of each of the side surface portions212 around the lower surface portion 211. The lower surface portion 211has an area corresponding to that of the lower surface of the pouch 200,while the side surface portions 212 have an area corresponding to thatof the side surface of the pouch 200. Further, the upper surfaceportions 213 formed at both edges of the lower surface portion 211 havea total area corresponding to an area of the upper surface of the pouch200. In addition, the sheath 210 encloses the sides of the case 120 fromthe lower surface to the side surfaces of the case 120 in rounding.Specifically, the sheath 210 of the case 120 makes the case 120 haverounded sides, so as to reduce the contact area of the case with theelectronic device, thereby facilitating insertion and separation of thecase 120 in and from the electronic devices when the case 120 isinserted into and separated from the electronic devices.

The sheath 210 is adhered to the case 120 by a separate adhesive so asto completely enclose the exterior surface of the case 120, therebyreinforcing the strength of the pouch 200. Therefore, the sheath 210 ismade of a material having a mechanical strength higher than that ofmaterial for the case 120, for example stainless steel or syntheticresin. Further, the sheath 210 is preferably formed as a foil.Furthermore, the sheath 210 is preferably formed with a thickness ofless than 0.1 mm. When the sheath 210 has a thickness of more than 0.1mm, the pouch has a reduced inner volume due to the thickness increaseof the sheath 210 within the predetermined entire volume, so that thecapacity of the secondary battery is remarkably reduced.

On the other hand, the sheath 210 may have information relating to oneof a serial number, manufacturing data, and manufacturer of thesecondary battery, printed on the exterior surface thereof.

The first and second electrode tabs 111 a and 115 a extending outwardfrom is the case 120 protrude outward from the sheath 210. The first andsecond electrode tabs 111 a and 115 a which protrude outward areconnected to a protection circuit board (not shown) which is mountedoutside of the secondary battery, i.e. in the electronic device.

The electronic device may be a portable mobile phone 300.

The portable mobile phone 300 is provided at a side thereof with abattery mounting portion 310 having a desired space in which thesecondary battery is inserted, and a cover 320 for covering the exteriorsurface of the battery mounting portion 210. The cover 320 has a fixingbutton 321 installed thereto so as to fix the cover 320 to the portablemobile phone 300. The portable mobile phone 300 is provided with theprotection circuit board, which is connected to the first and secondelectrode tabs 111 a and 115 a of the secondary battery 100, mountedaround the battery mounting portion 310 in the portable mobile phone300.

Hereinafter, the sheath according to another embodiment of the presentinvention will be described.

FIG. 3 is a plan view showing the sheath according to another embodimentof the present invention. The same reference numerals are used to denotethe same part of the sheath 210 a of the present embodiment as that ofthe sheath 210 according to the embodiment of FIG. 1B, and thedescription relating to the same parts will be omitted.

Referring to FIG. 3, the sheath 210 a according to another embodiment ofthe present invention has a lower surface portion 211, side surfaceportions 212, upper surface portions 213, and a rear surface portion214. The rear surface portion of the sheath 210 a may be formed at anedge of the lower surface portion 211 so as to extend perpendicular tothe side surface portions 212. The rear surface portion 214 has an isarea corresponding to the rear surface of the pouch 200 which isopposite to a front surface through which the first and second electrodetabs 111 a and 115 a extends outward, and comes into complete contactwith the rear surface of the pouch 200, so as to reinforce the strengthof the rear surface of the pouch 200. The rear surface portion 214 isintegrated with the lower surface portion 211 of the sheath 210 a, orformed separately from the lower surface portion 211 and attached to thelower surface portion 211 of the sheath 210 a.

Hereinafter, the sheath according to another embodiment of the presentinvention will be described.

FIG. 4 is a perspective view showing the sheath according to anotherembodiment of the present invention. The same reference numerals areused to denote the same part of the sheath of the present embodiment asthat of the sheath according to the embodiment of FIG. 1B, and thedescription relating to the same parts will be omitted.

Referring to FIG. 4, the sheath 210 b includes a left side sheath 216 aand a right side sheath 216 b, which are assembled with each other atboth sides of the pouch 200 and reinforce the strength of the pouch 200.Therefore, the left side sheath 216 a and the right side sheath 216 bhave open sides which are opened to opposite sides of the pouch,respectively. The left side sheath 216 a and the right side sheath 216 brespectively have a lower surface portion 211 b and 211 b′, a sidesurface portion 212 b and 212 b′, and an upper surface portion 213 b and213 b′. The lower surface portion 211 b and 211 b′ and the upper surfaceportion 213 b and 213 b′ respectively have an area corresponding to ahalf area of an upper surface or a lower surface of the pouch 200.Further, each of the side surface portions 212 b and 212 b′ of the leftside sheath is 216 a and the right side sheath 216 b has an areacorresponding to a side surface of the pouch 200. Further, each of theleft side sheath 216 a and the right side sheath 216 b further has arear surface portion 214 b and 214 b′ formed with an area correspondingto a half area of the rear surface of the pouch 200. Preferably, each ofthe left side sheath 216 a and the right side sheath 216 b forming thesheath 210 b may be integrally formed by molding. The left side sheath216 a and the right side sheath 216 b respectively cover the pouch 200and adhere to the pouch 200 by a separate adhesive.

Hereinafter, a sheath according to another embodiment of the presentinvention will be described.

FIG. 5 is a perspective view showing the sheath according to anotherembodiment of the present invention. The same reference numerals areused to denote the same part of the sheath of the present embodiment asthat of the sheath according to the embodiment of FIG. 1B, and thedescription relating to the same parts will be omitted.

Referring to FIG. 5, the sheath 210 c according to another embodiment ofthe present invention includes an upper sheath 217 a and a lower sheath217 b, which are coupled to cover the pouch 200 from sides of the pouch200 so as to completely reinforce the strength of the pouch 200. Thecoupled upper sheath 217 a and lower sheath 217 b make an opening thatopen toward the front surface of the pouch 200. Further, the uppersheath 217 a has an upper surface portion 213 c, and side surfaceportions 212 c formed at both edges of the upper surface portion 213 c.The lower sheath 217 b includes a lower surface portion 211 c and sidesurface portions 212 c′ formed at both edges of the lower surfaceportion 211 c. The upper and lower surface portions 213 c and 211 crespectively have an area corresponding to that of a lower surface or anis upper surface of the pouch 200. Each of the upper sheath 217 a andthe lower sheath 217 b further includes a rear surface portion 214 cformed with an area corresponding to that of a rear surface of the pouch200. Preferably, each of the upper and lower sheaths 217 a and 217 bforming the sheath 210 c may be integrally formed by molding. The upperand lower sheaths 217 a and 217 b are coupled to upper and lower sidesof the pouch 200, respectively, and adhere to the pouch 200 by aseparate adhesive.

Hereinafter, the operation of the secondary battery according to thepresent invention constructed as described above will be described.

The electrode assembly 110 is inserted into the recess 121 a of thepouch 200. The pouch 200 receiving the electrode assembly 110 isenclosed with the sheath 210, of which both sides are rounded. The firstand second electrode tabs 111 a and 115 a are protruded from a frontside of the sheath 210 and electrically connected to the protectioncircuit board, so as to form the secondary battery.

Since the sheath 210 enclosing the exterior surface of the case 120 hassides formed in rounding, the pouch 200 makes a smooth contact with thecontact surface of the battery mounting portion 310 when the secondarybattery 100 is mounted in the battery mounting portion 310. Further, thecontact surface between the sides of the pouch 200 and the inner surfaceof the battery mounting portion 310 is reduced to make it possible tofacilitate attachment and detachment of the secondary battery 100.Furthermore, the sheath 210 made of stainless steel or synthetic resin,etc. encloses the exterior surface of the case 120, thereby preventingdamage to the soft case 120. Here, the secondary battery 100 is mountedin a portable mobile phone so that the first and second electrode tabs111 a and 115 a are connected to the protection circuit board mountedadjacent to the battery mounting portion 310.

When the secondary battery 100 is mounted in the battery mountingportion 310 of the portable mobile phone 300, the cover 320 is fixed tothe portable mobile phone 300 by the fixing button 321, so as to coverthe battery mounting portion 310.

Although a preferred embodiment of the present invention has beendescribed for illustrative purposes, those skilled in the art willappreciate that various modifications, additions and substitutions arepossible, without departing from the scope and spirit of the inventionas disclosed in the accompanying claims.

What is claimed is:
 1. A secondary battery comprising: an electrodeassembly comprising a first electrode plate, a second electrode plate,and a separator interposed between the first electrode plate and thesecond electrode plate; a case for receiving the electrode assembly; anda sheath for enclosing the case, the sheath having a sheet shape andincluding a lower surface portion covering a lower surface of the case;a first side surface portion connected to one side edge of the lowersurface portion and covering a first side portion of the case; a secondside surface portion connected to the other side edge of the lowersurface portion and covering a second side portion of the case; a firstupper surface portion bounded by one end of the sheath, two side edgesof the sheath and one side surface portion of the sheath connected tothe first side surface portion of the sheath and covering a portion ofthe area of an upper surface of the case; a second upper surface portionbounded by one end of the sheath, two side edges of the sheath and oneside surface portion of the sheath connected to the second side surfaceportion of the sheath and substantially covering the remaining area ofthe upper surface of the case; and a rear surface portion connected atan edge of the lower surface portion for covering a rear portion of thecase, wherein the total area of the first and second upper surfaceportions of the sheath is approximately the same as the area of theupper surface of the case, and an end of the first upper surface portionis disposed adjacent to an end of the second upper surface portion onthe upper surface of the case.
 2. The secondary battery as claimed inclaim 1, wherein all the surface portions of the sheath are onecontinuous piece.
 3. The secondary battery as claimed in claim 1,wherein the sheath has the information printed on an exterior surfacethereof and including the data related to the secondary battery.
 4. Thesecondary battery as claimed in claim 1, wherein the secondary batteryis an inner pack type battery.
 5. The secondary battery as claimed inclaim 1, wherein the sheath has a mechanical strength higher than thatof the case.
 6. The secondary battery as claimed in claim 5, whereineach of the first and second side surface portions has rounded sectionscorresponding to a section of the side portion of the case.
 7. Thesecondary battery as claimed in claim 1, wherein the first upper surfaceportion has a surface area which is the same as that of the secondsurface portion.
 8. The secondary battery as claimed in claim 1, whereinthe sheath is made of stainless steel.
 9. The secondary battery asclaimed in claim 1, wherein the sheath is formed as a foil.
 10. Thesecondary battery as claimed in claim 1, wherein the sheath is made ofsynthetic resin.
 11. The secondary battery as claimed in claim 1,wherein the sheath has a thickness of less than 0.1 mm.
 12. Thesecondary battery as claimed in claim 1, wherein the lower surfaceportion is in contact with a lower surface of the case, and the sidesurface portions are in contact with a side surfaces of the case, andthe upper surface portions are in contact with an upper surface of thecase.
 13. The secondary battery as claimed in claim 1, wherein the lowerside surface portion, the upper side surface portions and the sidesurface portions are integrally formed by molding.